Lesson 1Appearance and functional testing evidence — paint/film/coating, gloss, texture, and mechanical testsExplains how to document appearance and functional testing for trim and coated parts, including paint, film, and coating tests, gloss and texture evaluations, and mechanical performance tests required to show compliance with specifications.
Customer appearance requirements and AARsPaint, film, and coating performance testsGloss, color, and texture evaluationsMechanical and functional test methodsPhotographic and sample board evidenceLesson 2Packaging, labelling, and shipping documentation to include in PPAPExplains packaging, labelling, and shipping documentation required in PPAP, including packaging specifications, labelling content, traceability, and evidence that logistics methods protect part quality through the supply chain.
Packaging specifications and approvalsLabel content and barcoding rulesTraceability and lot identificationTransit testing and damage preventionLogistics controls and work instructionsLesson 3Engineering Change Documentation and Design Failure Modes to includeCovers when engineering change documentation is required, how to reference ECNs and deviations, and which design failure modes must be addressed in PPAP to demonstrate that risks from design changes are fully evaluated and controlled.
Triggers for engineering change recordsDocumenting ECNs, waivers, and deviationsUpdating DFMEA and design recordsCommunicating changes to customersTraceability from change to validationLesson 4Supplier performance and subcontractor submittals to includeCovers how to include supplier and subcontractor documentation in PPAP, define flow-down requirements, collect sub-supplier PPAPs, and evaluate supplier performance indicators relevant to the submitted part.
Identifying critical suppliers and servicesFlow-down of customer requirementsSub-supplier PPAP and approvalsMonitoring supplier performance KPIsManaging supplier risks and escalationsLesson 5Dimensional Results and Material Test Reports — sample sizes, reporting formatDescribes how to report dimensional layouts and material test results, including sample size selection, layout strategy, reporting formats, correlation to drawings and specifications, and handling nonconformities and re-measurement.
Selecting parts and sample sizesBallooned drawings and dimension mappingDimensional report formats and unitsMaterial and performance test summariesHandling out-of-tolerance dimensionsLesson 6Control Plan — format (process and product controls), linkage to PFMEA and inspection pointsDetails how to structure a control plan for process and product controls, align it with PFMEA, define inspection points and reaction plans, and maintain traceability from risks to controls across the manufacturing process.
Control plan types and required columnsLinking PFMEA causes to controlsDefining product and process characteristicsInspection frequency and sample strategyReaction plans for out-of-control resultsLesson 7Measurement System Analysis (MSA) — plan for dimensional and visual inspection gaugesDescribes how to plan and document MSA for dimensional and visual gauges, including GRR studies, attribute agreement analysis, acceptance criteria, and how to align MSA scope with critical and special characteristics.
Selecting gages for MSA studiesVariable GRR study planningAttribute agreement for visual checksInterpreting MSA indices and criteriaDocumenting MSA in the PPAP fileLesson 8Part Submission Warrant (PSW) — how to complete fields and attach referencesExplains the role of the PSW as the formal customer approval document, how to complete each field correctly, reference drawing and test reports, and how to link the PSW to supporting PPAP evidence and submission levels.
PSW purpose and link to PPAP approvalKey PSW fields and completion rulesReferencing drawings, tests, and reportsSubmission levels and customer specificsCommon PSW errors and how to avoid themLesson 9Initial Process Studies (short-term and long-term) — stability, control charts, and sample collectionClarifies expectations for initial process studies, distinguishing short-term and long-term data, use of control charts, stability and capability assessment, and how to select sampling points that represent real production conditions.
Objectives of initial process studiesChoosing characteristics and locationsX-bar, R, and I-MR chart selectionAssessing stability and special causesDocumenting study results in PPAPLesson 10Design Records (drawing revisions, BOM, material specs) — required content for this partDefines required design records for the part, including drawings, BOM, material and performance specifications, and customer standards, and explains how to control revisions and ensure that PPAP evidence matches the released design.
Customer drawings and 3D modelsBill of materials and component traceabilityMaterial and performance specificationsRevision control and change historyAligning records with PPAP evidenceLesson 11Capability Studies (Cp, Cpk) — data collection plan, sample size, and interpreted acceptance criteriaExplores capability study requirements for special characteristics, including Cp and Cpk calculations, data collection plans, minimum sample sizes, stability checks, and how to interpret results against customer acceptance criteria.
Selecting characteristics for capabilityShort-term vs long-term capability dataSample size and subgroup definitionCalculating Cp, Cpk, and PpkInterpreting results and improvement plansLesson 12Process Flow Diagram — symbols, mapping for moulding and downstream operationsExplains how to build a process flow diagram using standard symbols, mapping moulding and downstream operations, linking to PFMEA and control plan, and ensuring all value-added and inspection steps are represented clearly.
Standard symbols and notation rulesDefining process boundaries and scopeDetailing molding and secondary stepsLinking flow to PFMEA and control planVersion control and change updatesLesson 13PFMEA — structure, severity/occurrence/detection scales, and examples for trim part failure modesDetails how to structure PFMEA for the trim part, define functions and failure modes, apply severity, occurrence, and detection scales, and develop effective actions that link to the control plan and process documentation.
Defining process steps and functionsIdentifying failure modes and effectsRating severity, occurrence, detectionAction prioritization and follow-upAligning PFMEA with control plan
